Volkswagen Golf 5 2004- VW Rabbit GTI 2006

Volkswagen Golf 5 2004- VW Rabbit GTI 2006

97 - 1 VAS 5051 / 5052 General information On Board Diagnostic (OBD) program functions must be carried out using either the Vehicle Diagnostic, Testing and Information System VAS 5051 or Vehicle Diagnostic and Service System VAS 5052 . Specific service, On Board Diagnostic (OBD) and component / function troubleshooting procedures are available via tester operating modes "Guided Fault Finding" or "Guided Functions" . Additional information: Self Study Program - Course Number 811203 "VAS 5052 Design and Function" VAS 5051 / VAS 5052 Operating instructions VAS 5051 / VAS 5052 Operating mode "Administration" .

- Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, Vehicle Diagnostic, Testing and Information System VAS 5051 / 5052 , connecting .

Scan Tool (ST) and Test Equipment, Safety Precautions Warning! „ Due to weight, size and need for manual operation of test instruments while vehicle is driven on public roads, instrument must be used only with a Driver operating the vehicle and an Instrument Operator operating the test equipment. „ Do not use Instrument with Driver only. Always use two persons to conduct test. „ Do not place Instrument on lap of Driver or front seat passenger because emergency stop may dislodge Instrument and cause airbag deployment with risk of injury to Instrument Operator.

Page 1 / 3 VAS 5051 / 5052 Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->

„ Place Instrument in rear seating area and secure by available safety belt. „ Instrument Operator must be seated in the other rear seating position, after sliding front passenger seat and moving the seat back as far forward as possible. Do not activate the seat back release lever. „ Instrument Operator must wear safety belt. Vehicle Diagnostic, Testing and Information System VAS 5051 / 5052 , connecting Special tools, testers and auxiliary items required „ Vehicle Diagnostic, Testing and Information System VAS 5051/5052 (VAS 5051 A version shown as example only) „ Diagnostic cable VAS 5051/6A (5 m) „ Diagnostic cable VAS 5051/5A (3 m) Page 2 / 3 VAS 5051 / 5052

Note: „ Only the diagnostic cables listed above are to be used. Cables are equipped with CAN-wires that permit diagnosis of CAN-Bus systems. Connecting: - Engage parking brake. - For vehicles with automatic or DSG transmission, bring selector lever into position "P" or "N" . - For vehicles with manual transmission, bring shift lever into neutral position. - Switch off all electrical consumers. - With ignition switched off, connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 with diagnostic cable VAS 5051/6A to Data Link Connector (DLC) located under left lower portion of instrument panel - arrow - .

- Switch ignition on. - Select operating mode "Guided Fault Finding" , "Vehicle Self Diagnosis" or "Guided Functions" The DTC memory of all control modules will be checked: - Enter information as prompted. Where required, press ">" to confirm - Follow tester prompts Page 3 / 3 VAS 5051 / 5052

97 - 2 Fuse Panel Fuse panel, removing and installing Special tools, testers and auxiliary items required „ Trim removal wedge VAS 3409 Caution! „ When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting .

„ When removing switches, trim, covers or displays, prevent damage to visible areas of the interior by always applying appropriate tape to area surrounding the component, and the tools being used (screwdrivers, wedges etc.). Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting .

- Remove drivers storage compartment where applicable . Repair Manual, Body Interior, Repair Group 68, Page 1 / 2 Fuse Panel

- Remove left instrument panel side cover - 1 - by inserting trim removal wedge VAS 3409 or a screwdriver into recess - 2 - and pry off cover - 1 - in direction of - arrow - . - Remove fuse assignment card - 1 - from fuse panel - 2 - . - Remove screws - arrows - and guide fuse panel - 1 - outward as far as cable lengths permit. Installing: Install in reverse order of removal. Page 2 / 2 Fuse Panel

97 - 3 Relay Panels Relay/fuse panel under left instrument panel, removing and installing Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting .

Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting . - Remove drivers compartment where applicable . Repair Manual, Body Interior, Repair Group 68, - Remove relays - arrows - from relay carrier. Note: „ The number of relays is dependent on vehicle equipment.

Page 1 / 4 Relay Panels

- Release retaining tab in direction of - arrow - then press relay holders - 1 - out of relay panel. - Release retainer - 1 - for relay panel in direction of - arrow - and remove relay panel. Installing: Install in reverse order of removal, noting the following: - First clip connector into relay carrier. - Place relay carrier - 2 - into guide - 1 - and then engage relay carrier. Relay panel integrated with Vehicle Electrical System Page 2 / 4 Relay Panels

Control Module J519 , removing and installing Note: „ The relay panel integrated with Vehicle Electrical System Control Module J519 is permanently attached and cannot be serviced separately.

„ If Vehicle Electrical System Control Module J519 is to be replaced, the work procedure to read out the coding stored in the module must always be performed 97-5, Vehicle Electrical System Control Module J519 , coding . Removing: Caution! „ Switch off all electrical consumers. „ Switch ignition off and remove ignition key. - Remove drivers footwell cover .

Repair Manual, Body Interior, Repair Group 68, - Remove drivers storage compartment where applicable . Repair Manual, Body Interior, Repair Group 68, - Disengage electrical connection lock - 1 - in direction of - Page 3 / 4 Relay Panels

arrow A - . - Disengage electrical connection lock - 2 - at Vehicle Electrical System Control Module J519 in direction of - arrow B - . Note: „ Harness connectors of Vehicle Electrical System Control Module J519 and of relay carrier at vehicle electrical system control module, at left instrument panel, can only be disconnected if lock is brought into position "OPEN" beforehand.

- Disconnect all electrical connections to relay panel. Note: „ The number of electrical connections depends on vehicle equipment.

- Unclip Vehicle Electrical System Control Module J519 with relay panel from latches - arrows C - . - Pull Vehicle Electrical System Control Module J519 with relay panel downward and out of bracket in opposite direction of travel. Installing: Install in reverse order of removal, noting the following: Note: „ Electrical connection locks can only be brought into position " CLOSE" when all connections are connected "correctly" . Page 4 / 4 Relay Panels

97 - 4 Electronics Boxes (E-Boxes) E-Box in engine compartment - left, removing and installing Note: „ Depending on equipment, two different E-boxes are used: either "E-Box High" or "E-Box Low" .

The following illustrations show "High" version. Removal and installation of "Low" version is the same. Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting .

Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting . - Slide retainers - 1 - in direction of - arrow - and remove E-box cover - 2 - upward. Note: „ Mark location of cables connected to E-box. Page 1 / 6 Electronics Boxes (E-Boxes)

- Remove nuts - 1 - . - Open - arrows - covers - 2 - for wire guides at E-box. - Remove wires from connecting pins. - Unclip wires from wire guides. - Remove central screw - arrow - for E-box - 1 - . Note: „ Removing the central screw - arrow - presses off the E-box - 1 - upward from E-box bracket. - Remove E-box - 1 - upward from E-box bracket.

Note: Page 2 / 6 Electronics Boxes (E-Boxes)

„ In order to remove flat terminal housing - 1 - , battery and battery console must be removed. - If necessary, remove air filter housing. - Remove battery 27-5, Battery, removing and installing . - Remove screws - arrows - for battery console - 1 - . - Remove battery console - 1 - from vehicle. Page 3 / 6 Electronics Boxes (E-Boxes)

- Press straps on E-box bracket apart from each other - arrows B - and slide flat terminal housing - 1 - sideways - arrow A - from E-box bracket. only vehicles with "High" E-box version: - Press straps on E-box bracket apart from each other - arrows C - and slide flat terminal housing - 2 - toward front - arrow D - from E-box bracket.

all vehicles: - Remove nuts - arrows - of E-box bracket - 1 - . Note: „ Depending on vehicle equipment, an auxiliary relay panel may be installed. Page 4 / 6 Electronics Boxes (E-Boxes)

- Pull E-box bracket - 1 - upwards from studs as far as cable lengths permit. - Unclip auxiliary relay carrier - 1 - sideways from E-box bracket - 2 - . - Remove E-box bracket - 2 - from vehicle. Installing: Install in reverse order of removal, noting the following: - Reconnect wires - 1 - to E-box in allocation marked during removal Electrical Wiring Diagrams, Troubleshooting and Component Locations binder . - Tighten all fasteners according to values in table 97-6, E-Box in engine compartment, tightening torques . Page 5 / 6 Electronics Boxes (E-Boxes)

- Place cover - 2 - onto E-box and slide retainers - 1 - in direction of - arrow - until engaged.

Note: „ Always confirm E-Box cover - 2 - is correctly engaged. Page 6 / 6 Electronics Boxes (E-Boxes)

97 - 5 Control Modules Vehicle Electrical System Control Module J519 Note: „ The relay panel integrated with Vehicle Electrical System Control Module J519 is permanently attached and cannot be serviced separately. „ If Vehicle Electrical System Control Module J519 is to be replaced, the work procedure to read out the coding stored in the module must always be performed 97-5, Vehicle Electrical System Control Module J519 , coding . General information: Vehicle Electrical System Control Module J519 controls the function of the following components/systems: „ Electric load management „ Exterior light control „ Turn signal control „ Wipers, rear window „ Heated rear window „ Interior light control „ Shift-/selector gate illumination „ Terminal control „ Dimming, instrument illumination „ Fuel Pump (FP) supply Page 1 / 14 Control Modules

„ Pre-energizing of generator „ Horn The following functions can be adapted: „ Erase learned values and set standard adaptation values „ Adjust Coming Home Time (equipment dependent) „ Adjust Leaving Home Time (equipment dependent) „ Set rear window heater "on time" „ Switch footwell lights on and off „ Switch highway signaling on and off „ Set load management „ Set headlamp cleaning system "on time" 97-5, Headlamp washer system, adaptation Note: „ Adaptations listed above are dependent on vehicle equipment level and market version.

„ "Highway signaling" , "comfort-flashing" , or "tap signaling" means that turn signals are activated multiple times (1-5 times) when turn signal lever is tapped once (signal cycles).

„ Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams and Component Locations Page 2 / 14 Control Modules

On Board Diagnostic (OBD), functions: Vehicle Electrical System Control Module J519 is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot Vehicle Electrical System Control Module J519 malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" . Vehicle Electrical System Control Module J519 , removing and installing Note: „ If Vehicle Electrical System Control Module J519 is to be replaced, the work procedure to read out the coding stored in the module must always be performed 97-5, Vehicle Electrical System Control Module J519 , coding .

Removing: Remove relay panel integrated with Vehicle Electrical System Control Module J519 97-3, Relay panel integrated with Vehicle Electrical System Control Module J519 , removing and installing Installing: Install relay panel integrated with Vehicle Electrical System Control Module J519 97-3, Relay panel integrated with Vehicle Electrical System Control Module J519 , removing and installing Vehicle Electrical System Control Module J519 , checking with Output Diagnostic Test Mode (DTM) The function of many electrical components can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519 .

- Connect Vehicle Diagnosis, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: Page 3 / 14 Control Modules

- Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "J519 - output DTM, sequential (Repair Group 97)" - Press ">" to confirm.

- Select "1 - Output Diagnostic Test Mode (DTM) for an individual component" - Search and select appropriate light or switch component from menu, or - Select "2 - Output Diagnostic Test Mode (DTM) for all actuators" - Follow tester prompts Vehicle Electrical System Control Module J519 , coding - Connect Vehicle Diagnosis, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 . - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" Page 4 / 14 Control Modules

- Select "Coding" - Press ">" to confirm. - Follow tester prompts Headlamp washer system, adaptation The "active time" of headlamp washer system can be adjusted variably between 0 seconds and 12.75 seconds. - Connect Vehicle Diagnosis, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "Adapting headlamp washer system" - Press ">" to confirm.

- Follow tester prompts Data Bus On Board Diagnostic Interface J533 General information: The Data Bus On Board Diagnostic Interface J533 "Gateway" is no longer integrated with the instrument cluster. It is now a separate control module. "J533" performs the following functions: „ Performs data exchange between CAN-Bus systems "CAN-Bus powertrain" , "CAN-Bus comfort" and "CAN-Bus Infotainment" Page 5 / 14 Control Modules

„ Transfers diagnostic data of CAN-Bus systems onto K-wire and vice-versa, allowing data from Vehicle Diagnosis, Testing and Information System VAS 5051/5052 to be utilized Note: „ If Data Bus On Board Diagnostic Interface J533 is to be removed, the work procedure to read out the coding stored in the module must always be performed 97-5, Data Bus On Board Diagnostic Interface J533 , replacing .

„ Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams and Component Locations On Board Diagnostic (OBD), functions: Data Bus On Board Diagnostic Interface J533 is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot Data Bus On Board Diagnostic Interface J533 malfunctions by performing OBD program using Vehicle Diagnosis, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" . Data Bus On Board Diagnostic Interface J533 , replacing - Connect Vehicle Diagnosis, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 . - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; Page 6 / 14 Control Modules

90-97)" - Select "01 - Self-diagnosis" - Select "Diagnostic interface for databus" - Select "Functions" - Select "Diagnostic interface for databus, replacing" - Press ">" to confirm. - Follow tester prompts Data Bus On Board Diagnostic Interface J533 , removing and installing Note: „ Before removing Data Bus On Board Diagnostic Interface J533 , the work procedure to read out the coding stored in the module must always be performed 97-5, Data Bus On Board Diagnostic Interface J533 , replacing .

Removing: Caution! „ Switch off all electrical consumers. „ Switch ignition off and remove ignition key.

- Remove drivers footwell cover . Repair Manual, Body Interior, Repair Group 68, Page 7 / 14 Control Modules

- Disengage electrical connection lock - 1 - and disconnect from Data Bus On Board Diagnostic Interface J533 - 2 - . - Press mounting pins - 3 - together - arrows - and from holes. Installing: Install in reverse order of removal. Comfort System Central Control Module J393 General information: Comfort System Central Control Module J393 performs the following functions: „ Sunroof control (issues enabling) „ Window regulator control (issues enabling) „ Central locking system control „ Anti-theft warning system control „ Radio receiver „ Rear lid closing „ Comfort operation Some of the functions listed above can be adapted 97-5, Comfort System Central Control Module J393 , adapting .

Note: „ Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams and Component Locations On Board Diagnostic (OBD), functions: Page 8 / 14 Control Modules

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